In October 2010, I consulted with my Dad, the master mechanic, and I decided that I would like to retire my hardy 4 speed automatic for a more utile 5 speed transmission. As a pseudo-totalitarian, simply installing the necessary parts would not be enough; each part would have to be inspected for long-term use, be upgraded if proven upgrade units WERE available, and since I would have the opportunity to complete most of the project off the car, I wanted to protect and beautify the parts by a combination of plating, powder coating and painting. And so we began the witch hunt.
Being that the original T50 had over 200,000km, I knew it would need to have some internal parts replaced, but with our good friend Robert of EP importers in Nagasaki, we were able to source the best priced parts direct from Toyota Japan. They were cheaper than going through the local Dealership.
In realizing my own limits, I hired out the work I did not feel confident in doing myself. I did a lot of wrench turning, but by seeking professional help (hehe) this project came together quite well.
Completing an entire system at a time is exhaustive, but it's a comprehensive way to get everything the way you want it; no piece-meal or incomplete projects keeping you up at night.
PROJECT LENGTH OCT 2010-MAY 2012
Thanks Dad for your contribution, supervision and patience.
For helping me to find the parts, and for consultation, thanks be to:
Dugwillis
Warren
jma
Corolla Fiend
celica-fiend
JayWhit
Rasta Racer
Coldstar64
DiscoQuinn (Who needs to empty out his mailbox!)
Brian
Jeff Lange
Services & Parts Rendered
Victoria Powder Coat - Powder Coating... Duh!
Bullfrog Transmission - Transmission Rebuild
Key 2 Machine Shop - Resurfacing of Flywheel
LeJeune - Installation of Pedal, adjustment of the Brake Pedal, fabrication of the Clutch Line
Island Muffler and Brake - Exhaust work
Victoria Plating - Anodizing of Nuts and Bolts
EP Importers - Toyota OEM and TRD Performance Parts
PARTS LISZT AND PICTURES:
Transmission
T50 transmission w/ GTS Bell Housing - Used, Powder coated Gun Metal
Transmission Internals Needed
Input Shaft 33301-12010
Input Shaft Bearing 90365-30020
Rebuild Kit (with Bearings, Syncros, Gaskets and Seals) Kingomatic BK244-WS
Shift Fork 3rd/4th 33212-14010
Sleeve 3rd/4th 33364-14010
Shift Fork 5th/Rev 33214-14010
Sleeve 5th/Rev 33395-26010
Speedometer Gear (19 tooth) 33403-19135
Reverse Switch 84210-10051
Clutch Related
Clutch Cover - Used, OEM
Clutch Pressure Plate - Beck Arnley
Clutch Pressure Plate Bolts (X6), Generic M8X1.25
N.B. We'll be replacing these with OEM bolts when we swap the engine.
Clutch Fork - Used, Powder Coated Black
Clutch Fork Clips - Used, OEM
Clutch Fork Boot 31126-20070
N.B. We're keeping the OEM clutch while the 4A-C remains in the car.
Flywheel
OEM Flywheel - Used, Resurfaced
Pilot Bearing 90363-12003-77
Release Bearing - Nachi 40TRBC07-27SB
Release Bearing Hub - Used
Flywheel Bolts (X6) 90105-10042
Hydraulic System
Master Cylinder - Beck Arnley
Master Cylinder Clevis 90240-08006
Master Cylinder Clevis Pin 90468-16142
Master Cylinder Clevis Bushing 90386-08002
Master Cylinder Clevis Washer 90206-08001
Slave Cylinder - Beck Arnley
Slave Cylinder Soft Line 90947-02440
Hose Bracket Used, OEM
Hose Clip 96991-10080
Clutch Pedal
Clutch Pedal & Bracket - Used, Powder coated Black
Clutch Pedal Hinge Bolt with Washer 90080-11553
Clutch Pedal Hinge Collar Bushing X2 90386-13007
Clutch Pedal Hinge Collar 90387-10003
Clutch Pedal Pivot Bolt 90101-10015.
Clutch Pedal Rest Bolt 90101-10369
Clutch Pedal Rest lock nut 94110-51000
Clutch Pedal Rest Bolt Cushion (X2) 90541-06008
Clutch Pedal Return Spring 90507-14003
Clutch Pedal Foot Pads (X2) 31321-12030
N.B. Same part number as the 5speed Brake Pedal Pad
Mounting Parts & Hardware
OEM Transmission Crossmember - Used OEM, Powder coated Black
Trans Crossmember to Mount Bolts (X2) 91661-41018
Cusco Transmission Mount 116 912 A
Transmission Mount to Extension Housing Bolts (X2) 916912-B1020 X2
Slave Cylinder Mount Bolts (X2) 91611-B0825
Bell Housing Bolts (X2-75mm long) 90119-12042
Bell Housing Bolts (X2-55mm long) 90119-12168
Shifter & Related
TRD Short Shifter PTR04-20850-02
TRD Shift Knob PTR04-00000-05
Shifter Housing Rubber Boot 33555-12090
Shifter Gasket 33584-20010
Shifter Bushing 33548-14010
Shift Boot - Used, OEM
Secondary Shift Boot - Used, OEM
Gear Oil
Motul, Gear 300, SAE 75W90, 100% synthetic, 2L
Driveline
GTS Intermediate Shaft - Used, OEM
OEM Centre Bearing - Used, OEM
N.B. This part will be upgraded once our GTS rear end project is completed.
And now for the pictures:
INTERNAL PARTS
CLUTCH & RELATED
SHIFTER
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